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build your own full float dana 44?

Discussion in 'Builds and Fabricators Forum' started by 47v6, Jan 6, 2015.

  1. May 16, 2015
    oldtime

    oldtime oldtime

    St. Charles,...
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    OH I see...
    Then the factory assembled Powr Lok assembly should theoretically be as good as its going to get.

    I can only assume then that the Dana Spicer units had better quality control. (machining tolerance)

    I have 8 or 9 Powr Loks and I don't recall the ring gears being more that .003 out if I take my time aligning the ring to the case.
     
  2. May 18, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

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    Well, here we are. Almost 20 pages into an axle build. Ridiculous. I pressed on the bearings to the power lock case and re checked backlash, 0.009 and rechecked pattern. Little to no change. assembled the spindles/hubs and slid in the axle shafts and bolted on the lockout hubs. i need to use my shop to make a lot of sawdust so it needs buttoning up. The assembly is ready to go in now. I will be installing the stock outer grease seals to at least keep some of the gear oil out of the hubs. The ID of the seal has a larger diameter than the OD of the shaft, so its not going to be a seal but more of a dam. I will be using my existing GM disk setup that is now on my tapered D44. I will be using a bit more care in the bolt up of the caliper brackets to make sure they are centered over the disk and I will make sure when re installing the disk to the hub that I true everything up on my lathe. I feel that some of my braking issues stem directly from that. The brakes are good, but I want great.

    heres the obligatory pic.
    [​IMG]
     
  3. May 18, 2015
    wheelie

    wheelie beeg dummy 2024 Sponsor 2023 Sponsor

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    Excellent work, sir. Maybe I missed it but, what is your distance, WMS to WMS? Looks quite a bit wider than stock.
     
  4. May 18, 2015
    47v6

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    Please excuse my ignorance, but I assume WMS would be the inside of the hub where the wheel is affixed? If that is so, then WMS to WMS is just under 50 inches. Right now my D30 is wider than the stock d44 tapered axle my jeep rides on now.

    Before I can accept the "good work" comment, I will need to put a couple hundred miles on this axle. If it doesn't blow up, then I will accept your compliment.

    Thanks for reading.
     
  5. May 18, 2015
    Focker

    Focker That's a terrible idea...What time? Staff Member

    WA
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    Wheel Mating Surface

    Good mediocre work! :D
     
  6. Jun 21, 2015
    47v6

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    Full float going in today

    Pulled my d44 tapered. rescued it from the scrap heap. dint do anything to it other than change oil, replace pinion seal, new brakes and ran it for 800 miles. Either the axle bearings are bad or the endplay is really incorrect as I can take the shaft and move it in out, up and down clunk clunk style.:p

    don't care, ran fine, made no bad noises yet.

    new axle has spring perches welded on, spindles and brake caliper mount bolted on. ready for bearings and hubs.
    [​IMG]
     
  7. Jun 21, 2015
    47v6

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    Re: Full float going in today

    Did figure 8's for 20 minutes. no noises no problem no leaks no issues. Its considerably quieter than the old axle and seems to roll a lot easier. you cannot tell it has a power lock in it until you spin both wheels at the same time. This is just so cool.
     
  8. Jun 21, 2015
    47v6

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    Axle assembly is in. Fabbed the spring plates out of 3/8 plate, ordered new 1/2 U bolts, welded the spring perches on.
    [​IMG]
    Put it all back together and did figure eights for 20 minutes. you just don't even know there is a power lock in there until both tires spin at the same time. No noise. No leaks, No issues what so ever. This is just so cool. What a great project this has been. Thanks for all your help!
     
  9. Jun 21, 2015
    millennium falcon

    millennium falcon Member

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    Awesome! I am so proud of you right now!
     
  10. Jun 21, 2015
    Focker

    Focker That's a terrible idea...What time? Staff Member

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    Nice job... What's the total $ investment?

    I found this near me...

    "NOS Warn Dana 44 offset 19 spline full float kit with drive flanges (this is a rare find as they haven't built this in years ) also included is a TSM rear disc brake kit all items new in original boxes never installed. Early jeep CJ with Dana 44 rear 19 spline - $1500.00. "
     
    Last edited: Jun 21, 2015
  11. Jun 21, 2015
    uncamonkey

    uncamonkey Member

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    Sometimes a person has a bit of luck. Years ago I was in NM pouring some concrete and between pours we went out to play in my 3B. Broke the Powerlock. Went to the junk yard and pulled another out of an International PU, $50.00.
     
  12. Jun 21, 2015
    47v6

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    I don't really know what the total investment is. Some parts are new, rotors, gears, master install kit, power lock, seals, lug studs.. some is old but machined. the chevy D44 long side front shafts, the d30 drum spindles, the d30 drum hubs, used D 30 drum bearings. I doubt I have 1500 in the whole thing including calipers, axle housing and the rest. Might be close for all of it combined. I have read that the Warn Kit does not work with all disk brake conversions. some it does and some it does not. The machine work on the spindles is pretty elementary to make your own. Anyone with a small to mid sized lathe can do it. If you have a doner d27 or d30 that can be had for free and a doner d44 housing the cost is in the shafts and the locking hubs if thats what you want. the drive flanges can be had for 75bucks or so, maybe cheaper. 30 spline gives you a lot more options for lockers/power lock/ and axle shafts. I went 30 spline for this reason. For 30 spline you need to change case.

    None of this was hard to do. All of it took a lot of time and measuring. Gear set up took forever. dial indicator is an absolute must have. 1500 is too much in my opinion. I will never pay a lot for something I can do myself. I am pretty certain you can do this, minus the machine work too.

    maybe R&P can hook you up some.
     
  13. Jun 21, 2015
    wheelie

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    Re: Full float going in today

    great work, Chris.
     
  14. Jun 21, 2015
    47v6

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    Re: Full float going in today

    thanks.
    burnouts have a whole new meaning.
     
  15. Jun 22, 2015
    Focker

    Focker That's a terrible idea...What time? Staff Member

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    I knew it would be hard for you to put a figure on it. :)

    Good info and as repeatedly mentioned, nice job. I admire your determination and commitment. I on the other hand will have to go with a kit. Not that there's anything wrong with that. I've come to terms with the tapered axle I have but I'm intrigued by the FF application. I think it would be a nice option for flat towing to the hills. Keep up the great work, it's inspiring!
     
  16. Jun 22, 2015
    47v6

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    So complicated! how will i figure this out?;)
    [​IMG]
     
  17. Jun 22, 2015
    jeepermc

    jeepermc Active Member

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    Last time I was at Olympic 4x4 in Snohomish they had a flatty in the yard with an old school full float kit on the offset 44 in it... But that was a couple months ago now.
     
  18. Jun 22, 2015
    47v6

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    As a side effect of the conversion my brakes are much better. i think that the chevy caliper bracket with the tapered d44 hub/rotor assembly needs some spacers to make the caliper float/ride correctly. I now have better brakes but a pulsating brake pedal. I do not have a brake lathe that simulates the spindle with the appropriate tapered pieces so I may have gotten the cut on my rotor /hub assembly off slightly. My brakes are so much better now though.
     
  19. Jun 22, 2015
    Rozcoking23

    Rozcoking23 RUN & GET BIT! 2024 Sponsor

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    Not to criticize, are the calipers in the wrong position? being in the front of the axle would put the bleeder valve on the bottom making it harder to bleed.
     
  20. Jun 22, 2015
    54Willys

    54Willys New Member

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    Great Job !:drool:
     
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